Systems and methods for interchangeable induction heating systems

ABSTRACT

An induction heating system includes interchangeable secondary induction heating assemblies and/or secondary induction heating coil flux concentrators that are specifically configured for the particular type of weld being created and/or the particular weld joint where the weld is created. For example, the secondary induction heating assemblies and/or secondary induction heating coil flux concentrators may have specific physical configurations (e.g., shapes, contours, etc.) and/or include specific materials (e.g., ferrites) that are well suited for the particular type of weld being created and/or the particular weld joint where the weld is created. In certain embodiments, a robotic positioning system may be configured to move the secondary induction heating coil to an induction heating coil changing station to, for example, detach the secondary induction heating coil, and attach another secondary induction heating coil, thereby facilitating different secondary induction heating coils to be used for induction heating of different types of welds, for example. In addition, in certain embodiments, the robotic positioning system may be configured to move the secondary induction heating coil to the induction heating coil changing station to, for example, detach the secondary induction heating coil flux concentrator, and attach another secondary induction heating coil flux concentrator.

CROSS REFERENCE TO RELATED APPLICATION

This application is a Continuation of U.S. patent application Ser. No.14/921,782, entitled “SYSTEMS AND METHODS FOR INTERCHANGEABLE INDUCTIONHEATING SYSTEMS,” filed Oct. 23, 2015, and issued on Apr. 28, 2020, asU.S. Pat. No. 10,638,554, which is a Non-provisional US. PatentApplication of U.S. Provisional Application No. 62/096,271, entitled“SYSTEMS AND METHODS FOR INTERCHANGEABLE INDUCTION HEATING SYSTEMS,”filed Dec. 23, 2014, both of which are hereby incorporated by referencein their entireties.

BACKGROUND

The present disclosure relates generally to induction heating systemsand, more particularly, to interchangeable induction heating assemblies.

Induction heating may be used to pre-heat metal before welding orpost-heat the metal after welding. It is well known to weld pieces ofsteel (or other material) together. For example, pipes are often formedby taking a flat piece of steel and rolling the steel. A longitudinalweld is then made along the ends of the rolled steel, thus forming asection of pipe. A pipeline may be formed by circumferential weldingadjacent sections of pipe together. Other applications of welding steel(or other material) include ship building, railroad yards, tankertrucks, or other higher strength alloy welding.

When welding steel (or other material), it is generally desirable topre-heat the workpiece along the weld path. Pre-heating is used to raisethe temperature of the workpiece along the weld path because the fillermetal binds to the workpiece better when the weld path is pre-heated,particularly when high-alloy steel is being welded. Without pre-heating,there is a greater likelihood that the filler metal will not properlybind with the workpiece, and a crack may form, for example. Generally,the steel may be preheated to approximately 600° C. prior to welding.

BRIEF DESCRIPTION

Embodiments described herein include interchangeable secondary inductionheating assemblies and/or secondary induction heating coil fluxconcentrators that are specifically configured for the particular typeof weld being created and/or the particular weld joint where the weld iscreated. For example, the secondary induction heating assemblies and/orsecondary induction heating coil flux concentrators may have specificphysical configurations (e.g., shapes, contours, etc.) and/or includespecific materials (e.g., ferrites or other highly permeable materials)that are well suited for the particular type of weld being createdand/or the particular weld joint where the weld is created. In certainembodiments, a robotic positioning system may be configured to move thesecondary induction heating coil to an induction heating coil changingstation to, for example, detach the secondary induction heating coil,and attach another secondary induction heating coil, therebyfacilitating different secondary induction heating coils to be used forinduction heating of different types of welds, for example. In addition,in certain embodiments, the robotic positioning system may be configuredto move the secondary induction heating coil to the induction heatingcoil changing station to, for example, detach the secondary inductionheating coil flux concentrator, and attach another secondary inductionheating coil flux concentrator.

DRAWINGS

These and other features, aspects, and advantages of the presentdisclosure will become better understood when the following detaileddescription is read with reference to the accompanying drawings in whichlike characters represent like parts throughout the drawings, wherein:

FIG. 1 is a perspective view of an embodiment of an induction heatingsystem in accordance with the present disclosure;

FIG. 2 is a block diagram of an embodiment of an induction heatingsystem in accordance with the present disclosure;

FIG. 3 is a block diagram illustrating certain of the internalcomponents of an embodiment of an induction heating system in accordancewith the present disclosure;

FIG. 4 is a schematic of an embodiment of an induction heating assemblypositioned ahead of a welding arc produced by a welding torch inaccordance with the present disclosure;

FIG. 5 is a perspective view of an embodiment of the induction heatingassembly in accordance with the present disclosure;

FIG. 6 is a perspective view of an embodiment of a transformer inaccordance with the present disclosure;

FIG. 7 is a perspective view of an embodiment of an secondary inductionheating coil in accordance with the present disclosure;

FIGS. 8A and 8B are side views of embodiments of the induction heatingassembly, illustrating the quick disconnect features for groove weldsand fillet welds, respectively, in accordance with the presentdisclosure;

FIG. 9 is a side view of an embodiments of the induction heating system,illustrating the transformer and the secondary induction heating coil asseparate components that are independently positionable with respect toeach other, in accordance with the present disclosure;

FIG. 10 is a perspective view of an embodiment of a litz cable that maybe used to connect the transformer with a remotely located secondaryinduction heating coil in accordance with the present disclosure;

FIG. 11A is a side view of an embodiment of the inducting heating systemincluding a secondary connector in accordance with the presentdisclosure;

FIG. 11B is front view of the secondary connector of FIG. 11B;

FIG. 12 is a perspective view of an embodiment of the secondaryconnector in accordance with the present disclosure; and

FIGS. 13-16 illustrate various embodiments of integrated inductionheating assemblies for various different types of welds in accordancewith the present disclosure.

DETAILED DESCRIPTION

FIG. 1 is a perspective view of an embodiment of an induction heatingsystem 10 in accordance with the present disclosure. As illustrated inFIG. 1, the induction heating system 10 includes an induction powersupply 12 and an induction heating assembly 14 that function together topre-heat and/or post-heat a workpiece 16 (e.g., a fillet weld workpiecein the illustrated embodiment). For example, in certain embodiments, theinduction heating assembly 14 may be moved by a robotic positioningsystem relative to the workpiece 16 along a weld path either in front ofor behind a welding torch 18 that may also be moved by a roboticpositioning system such that the induction heating assembly 14 maypre-heat or post-heat the weld produced on the workpiece 16 by thewelding torch 18. The induction heating assembly 14 receives inductionheating power, coolant, and so forth, from the induction power supply 12via a first cable 20 (or cable bundle), and the welding torch 18receives welding power, welding wire, a gas supply, and so forth, from awelding power supply 22 via a second cable 24 (or cable bundle).

In certain embodiments, the induction power supply 12 providesalternating current (AC) power to the induction heating assembly 14 viathe cable 20. The AC power provided to the induction heating assembly 14produces an AC magnetic field that induce eddy currents into theworkpiece 16, thereby causing the workpiece 16 to be heated. Theinduction power supply 12 may be any power supply capable of outputtingsufficient power to the induction heating assembly 14 to produce theinduction heating of the workpiece 16. For example, in certainembodiments, the induction power supply 12 may be capable of outputtingpower up to 300 amperes, however, other embodiments may be capable ofgenerating greater output current (e.g., up to 700 amperes, or evengreater). In certain embodiments, the induction power supply 12 includesconverter circuitry as described herein, which provides the AC outputthat is applied to the induction heating assembly 14.

FIG. 2 is a block diagram of an embodiment of an induction heatingsystem 10 in accordance with the present disclosure. The system 10includes the welding power supply 22, a welding wire feeder 26, and thewelding torch 18. The welding power supply 22 may be a power converteror an inverter based welding power supply requiring a power source 28.Many different circuit designs may be provided in the power source, andmany different welding regimes may be envisaged (e.g., direct current,alternating current, pulsed, short circuit, etc.) Any of theseconventional circuits and process technologies may be used inconjunction with the present induction heating techniques. In otherembodiments, the welding power supply 22 may be a generator oralternator welding power supply which may include an internal combustionengine.

The welding power supply 22 may also include a user interface 30 foradjusting various welding parameters such as voltage and current, andfor connecting a power source 28, if required. Additionally, a gassource 32 may be coupled to the welding power supply 22. The gas source32 is the source of the shielding gas that is supplied to the weldingtorch 18. The gas source 32 also supplies shielding gas to an auxiliaryshielding gas diffuser 34. For example, in certain embodiments, the gassource 32 may supply argon gas. As will be appreciated, the shieldinggas is applied to the location of the liquid weld pool by the weldingtorch 18 and the auxiliary gas diffuser 34 to prevent absorption ofatmospheric gases which may cause metallurgical damage to the weld. Asshown, the welding power supply 22 is coupled to the welding wire feeder26. For example, the welding power supply 22 may be coupled to thewelding wire feeder 26 by a feeder power lead, a weld cable, a gas hose,and a control cable.

The welding wire feeder 26 shown in the illustrated embodiment provideswelding wire to the welding torch 18 for use in the welding operation. Avariety of welding wires may be used. For example, the welding wire maybe solid carbon steel, solid aluminum, solid stainless steel, compositeand flux cored wire, and so forth. The present embodiments may be usedwith any suitable type of electrode, and any suitable wire composition.Furthermore, the thickness of the welding wire may vary depending on thewelding application for which the welding wire is used. For example, thewelding wire may be 0.045, 0.052, 1/16, 3/32, ¼, or any other diameter.Furthermore, the welding wire feeder 26 may enclose a variety ofinternal components such as a wire feed drive system, an electric motorassembly, an electric motor, and so forth. The welding wire feeder 26may further include a control panel (not shown) that allows a user toset one or more wire feed parameters, such as wire feed speed. In theillustrated embodiment, the auxiliary shielding gas diffuser 34 is alsocoupled to the welding wire feeder 26 by a gas hose 36. However, thewelding wire feeder 26 may be used with any wire feeding processincluding gas operations (gas metal arc welding (GMAW)) or gaslessoperations (shielded metal arc welding (SMAW) or self-shielding fluxcored arc welding (FCAW)).

As shown, the welding wire is fed to the welding torch 18 through thecable 24. The cable 24 may also supply gas to the welding torch 18. Asfurther shown, a separate cable 38 couples the welding power supply 22to the workpiece 16 (typically via a clamp) to complete the circuitbetween the welding power supply 22 and the welding torch 18 during awelding operation.

The exemplary system 10 also includes the induction power supply 12 andthe induction heating assembly 14. As illustrated, the induction powersupply 12 includes a user interface 40. The user interface 40 mayinclude buttons, knobs, dials, and so forth to allow an operator toregulate various operating parameters of the induction power supply 12.For example, the user interface 40 may be configured to enable anoperator to set and adjust the frequency of the alternating currentproduced by the induction power supply 12. Similarly, the user interface40 may enable an operator to select a desired output temperature of asecondary induction heating coil 44 of the induction heating assembly14. The user interface 40 may also include one or more displaysconfigured to provide system feedback to the operator (e.g., real-timetemperature of the secondary induction heating coil 44, travel speed ofthe secondary induction heating coil 44 relative to the workpiece 16,and so forth). The induction power supply 12 is coupled to a transformer42 via the cable bundle 20. In certain embodiments, the transformer 42may be an air-cooled or a liquid-cooled system. For example, a firstconduit may enable flow of a coolant into the transformer 42, andanother conduit may enable flow of the coolant from the transformer to aheat exchanger or other device that removes heat from the coolant.

In certain embodiments, the alternating electrical current exits thetransformer 42 and is supplied to the secondary induction heating coil44 by electrical conductors 46. As discussed in detail below, theelectrical conductors 46 may have a hollow core and may also route theflowing coolant through the secondary induction heating coil 44. In theillustrated embodiment, the secondary induction heating coil 44 isdisposed proximate to the workpiece 16. As the alternating current flowsthrough the secondary induction heating coil 44, eddy currents aregenerated and induced within the workpiece 16. The eddy currents flowagainst the electrical resistivity of the workpiece 16, therebygenerating localized heat in the workpiece 16. As shown, the secondaryinduction heating coil 44 is positioned ahead of the welding torch 18.In other words, for a welding torch 18 operating and traveling in adirection 48, the secondary induction heating coil 44 is placed in frontof the welding torch 18 (i.e., along the weld joint and before a weldingarc 50 created by the welding torch 18). As a result, the secondaryinduction heating coil 44 heats a localized area 52 of the workpiece 16immediately ahead of the welding arc 50, thereby raising the temperatureof the localized area 52 just ahead of the welding arc 50.

As shown, the welding power supply 22 and the induction power supply 12may also be coupled. For example, the welding power supply 22 and theinduction power supply 12 may be coupled by a hard wire, through awireless connection, over a network, and so forth. As discussed indetail below, the welding power supply 22 and the induction power supply12 may exchange data and information during the operation of theexemplary system 10. More particularly, the welding power supply 22 andthe induction power supply 12 may function in cooperation (e.g., utilizefeedback from one another) to adjust various operating parameters of theexemplary system 10.

It should be noted that modifications to the exemplary system 10 of FIG.1 may be made in accordance with aspects of the present disclosure.Although the illustrated embodiments are described in the context of anarc welding process, the features of the present disclosure may beutilized with a variety of other suitable welding or cutting systems andprocesses. For example, the induction heating assembly 14 may be usedwith a plasma cutting system or with a plate bending system. Morespecifically, the induction heating assembly 14 may be disposed ahead ofa plasma cutter to increase the temperature of a localized area ahead ofthe plasma cut, thereby enabling increased cutting speeds. Furthermore,while the induction heating assembly 14 is positioned ahead of thewelding torch 18 in the present embodiment, the induction heatingassembly 14 may be positioned in other locations. For example, theinduction heating assembly 14 may be positioned behind the welding torch18 to provide a heat treatment to a weld location after the workpiece 16is welded and fused. Similarly, certain embodiments may include morethan one induction heating assembly 14 (i.e., a first induction heatingassembly 14 positioned ahead of the welding torch 18 to raise thetemperature of the localized area 52 prior to welding, and a secondheating assembly 14 positioned behind the welding torch 18 to provide aheat treatment of a weld location that has been fused).

FIG. 3 is a block diagram illustrating certain of the internalcomponents of the exemplary induction heating system 10 in accordancewith the present disclosure. As discussed above, the power source 28 maypower the welding power supply 22 and/or the induction power supply 12.The welding power supply 22 provides power to the welding wire feeder26, and the welding power supply 22 is coupled to the workpiece 16,thereby completing the circuit between the welding power supply 22 andthe welding torch 18 during a welding operation. The induction powersupply 12 generates an alternating electrical current that is suppliedto the transformer 42, which subsequently routes the current to thesecondary induction heating coil 44. As mentioned above, the weldingpower supply 22 and the induction power supply 12 may be coupled andconfigured to exchange information and data (e.g., operating parameters,settings, user input, etc.) to enable the welding power supply 22 andthe induction power supply 12 to function cooperatively.

The welding power supply 22 includes several internal components toregulate various operating parameters of the system 10. In theillustrated embodiment, the welding power supply 22 includes controlcircuitry 54, a processor 56, memory circuitry 58, and interfacecircuitry 60. The control circuitry 54 is configured to apply controlsignals to the welding power supply 22 and/or the welding wire feeder26. For example, the control circuitry 54 may provide control signals tothe welding wire feeder 26 relating to the voltage or current providedby the welding power supply 22. The control circuitry 54 may alsoprovide control signals for regulating the operation of the welding wirefeeder 26 such as pulse width modulated (PWM) signals to regulate a dutycycle for a motor assembly in the welding wire feeder 26, and so forth.

The control circuitry 54 is further coupled to the processor 56, memorycircuitry 58 and interface circuitry 60. The interface circuitry 60 iscoupled to the user interface 30 of the welding power supply 22. Asdiscussed above, the user interface 30 is configured to enable anoperator to input and control various settings of the welding powersupply 22. For example, the user interface 30 may include a menu forselecting a desired voltage or current output to the welding wire feeder26. Additionally, the user interface 30 may include a menu or list ofwelding processes or welding wire materials and diameters. As will beappreciated, different welding processes, welding wire materials, andwelding wire diameters may have different characteristics and mayrequire differing configurations for various operating parameters. Forexample, configuration parameters requiring differing values may includevoltage output, current output, wire feed speed, wire feed torque, andso forth. Preset values for such configuration parameters, as well asothers, may be stored in the memory circuitry 58 for each of a varietyof welding processes, welding wire materials, and welding wirediameters.

By way of example, a user may select a welding process from a menu of aplurality of different welding processes displayed on the user interface30 of the welding power supply 22. The user interface 30 communicatesthe selection of the welding process to the interface circuitry 60,which communicates the selection to the processor 56. The processor 56then retrieves the particular configuration parameters for the weldingprocess stored in the memory circuitry 58. Thereafter, the processor 56sends the configuration parameters to the control circuitry 54 in orderthat the control circuitry 54 may apply appropriate control signals tothe welding wire feeder 26. In certain embodiments, as discussed below,the control circuitry 54 of the welding power supply 22 may alsocommunicate the configuration parameters to the induction power supply12.

In the illustrated embodiment, the induction power supply 12 includescontrol circuitry 62, a processor 64, memory circuitry 66, and interfacecircuitry 68. The control circuitry 62 is configured to apply controlsignals to the induction power supply 12 and/or the transformer 42. Forexample, the control circuitry 62 may provide control signals relatingto the alternating electrical current (e.g., alternating currentfrequency) supplied by the induction power supply 12 to the transformer42. Additionally, the control circuitry 62 may regulate the operation ofa cooling system used with the induction power supply 12 and/or thetransformer 42. As mentioned above, the induction heating assembly 14may use air or a coolant to provide circulating cooling throughout theinduction heating assembly 14. For example, the control circuitry 62 mayregulate a flow of a liquid coolant through the transformer 42 and thesecondary induction heating coil 44 to maintain a desired temperature ofthe induction heating assembly 14.

The control circuitry 62 is further coupled to the processor 64, memorycircuitry 66, and interface circuitry 68. The interface circuitry 68 iscoupled to the user interface 40 of the induction power supply 12. Asmentioned above, the user interface 40 of the induction power supply 12enables an operator to regulate one or more operating parameters orsettings of the induction power supply system 12. For example, the userinterface 40 may enable a user to select a particular design of theinduction heating assembly 14 from a menu of designs. As will beappreciated, different secondary induction heating coil 44 designs mayhave different configuration parameters. For example, different designsmay have different maximum operating temperatures, and may requiredifferent frequencies of alternating current to achieve a desiredtemperature. Similarly, the coolant used to cool the induction heatingassembly 14 may have different configuration parameters (e.g., heattransfer coefficients, viscosities, flow rates, and so forth). Presetvalues for such configuration parameters, as well as others, may bestored in the memory circuitry 66. For example, the user interface 40may communicate a user selection of the secondary induction heating coil44 designs to the interface circuitry 68, which may communicate theselection to the processor 64. The processor 64 may then retrieve theparticular configuration parameters for the secondary induction heatingcoil 44 stored in the memory circuitry 66. Thereafter, the processor 64sends the configuration parameters to the control circuitry 62 in orderthat the control circuitry 62 may apply appropriate control signals tothe induction power supply 12 and the transformer 42.

As mentioned above, the welding power supply 22 and the induction powersupply 12 may be coupled to one another by a hard wire, wirelessconnection, network connection, or the like. In particular, the weldingpower supply 22 and the induction power supply 12 may be configured tosend and receive data and information to one another relating to theoperating of the system 10. For example, the welding power supply 22 andthe induction power supply 12 may communicate with one another tocoordinate the speed of the induction heating assembly 14 and thewelding torch 18 with respect to the workpiece 16. As will beappreciated, in certain embodiments, the secondary induction heatingcoil 44 and the welding torch 18 are both designed for automatedoperation. As a result, the welding power supply 22 and the inductionpower supply 12 may be coupled and configured to communicate andmaintain a constant distance between the secondary induction heatingcoil 44 and the welding arc 50, as the secondary induction heating coil44 and the welding torch 18 travel along the workpiece 16 in thedirection 48. For example, the welding torch 18 and the secondaryinduction heating coil 44 may each have sensors configured to measure atravel speed or temperature along the workpiece 16.

For further example, the welding power supply 22 may communicate a userselected welding process (i.e., a welding process selected by anoperator through the user interface 30) to the induction power supply12. More specifically, the control circuitry 54 of the welding powersupply 22 may communicate the welding process selection to the controlcircuitry 62 of the induction power supply 12. Thereafter, the controlcircuitry 62 of the induction power supply 12 may modify any of avariety of operating parameters based on the user selected weldingprocess. For example, the control circuitry 62 may begin or end theprocess, or regulate the frequency or amplitude of the alternatingcurrent provided to the secondary induction heating coil 44 or the flowrate of a coolant through the transformer 42 and/or the secondaryinduction heating coil 44 to achieve a desired maximum temperature ofthe secondary induction heating coil 44 based on the welding processselected. More specifically, for a selected welding process, theprocessor 64 may retrieve configuration parameters for the selectedwelding process from the memory circuitry 66 and send the configurationparameters to the control circuitry 62. Similarly, the control circuitry62 of the induction power supply 12 may send operating information ordata to the control circuitry 54 of the welding power supply 22. Forexample, the control circuitry 62 may send temperature data (e.g.,maximum temperature or real-time temperature) of the secondary inductionheating coil 44 to the control circuitry 54 of the welding power supply22. Thereafter, the control circuitry 54 of the welding power supply 22may adjust one or more operating parameters of the welding power supplyand/or welding wire feeder 26 in response to the data received from theinduction power supply 12. For example, the control circuitry 54 of thewelding power supply 22 may begin or end the welding process or adjustthe wire feed speed or torque of the welding wire feeder 26 based on thetemperature data of the secondary induction heating coil 44 receivedfrom the control circuitry 62 of the induction power supply 12. As willbe appreciated, for higher temperatures provided by the secondaryinduction heating coil 44 to the localized area 52 of the workpiece 16ahead of the welding arc 50, a slower wire feed speed may needed.

It should be noted that in certain embodiments, the power supplies 12,22 and associated control circuits used for generation and control ofinduction heating power and welding power may be joined. That is, someor all of the circuits may be provided in a single power supply, andcertain of the circuits may serve both functions (e.g., operatorinterface components). Additionally, a central controller may providecoordination and synchronization commands to both the welding/cuttingsystem and the induction system.

It should also be noted that while reference is sometimes made in thepresent disclosure to advancement or movement of the welding torch andadjacent induction heating system, depending upon the welding systemdesign, the welding torch 18 and induction heating assembly 14 mayindeed be displaced, while in other systems these may remain generallystationary, with the workpiece or workpieces being moved. Such may bethe case, for example, in certain robotic or automated operations, insubmerged arc applications, and so forth. Both scenarios are intended tobe covered by the present disclosure, and references to moving a torchand induction heating system should be understood to include anyrelative motion between these components and the workpiece orworkpieces.

FIG. 4 is a schematic of an embodiment of the induction heating assembly14 positioned ahead of the welding arc 50 produced by the welding torch18 in accordance with the present disclosure. As discussed above, thetransformer 42 is coupled to the induction power supply 12 via the cablebundle 20. The induction power supply 12 supplies an alternating currentto the transformer 42 through the cable bundle 20. For example, thealternating current may have a frequency from 5,000 Hz to 300,000 Hz,although other frequencies may be supplied as well. From the transformer42, the alternating current is supplied to the secondary inductionheating coil 44. Specifically, the alternating current exits thetransformer 42 through power connections 70 attached to a base 72 of thetransformer 42. In certain embodiments, the electrical conductors 46 arecoupled to the power connections 70, e.g., by soldering, brazing, orbolting. However, in other embodiments described herein, the electricalconductors 46 may be removably coupleable with the power connections 70to enable different secondary induction heating coils 44 to beinterchangeably coupled to the transformer 42. As mentioned above, theelectrical conductors 46 may have a hollow core, thereby enabling acoolant to flow through the electrical conductors 46 of the secondaryinduction heating coil 44 to regulate a maximum temperature of thesecondary induction heating coil 44. In other words, the electricalconductors 46 of the secondary induction heating coil 44 may carry thealternating current and a coolant flow. As shown, in certainembodiments, the transformer 42 may be supported by a top plate 74 and abottom plate 76. In certain embodiments, the top and bottom plates 74,76 may be formed from a ceramic or other electrically insulatingmaterial.

FIG. 5 is a perspective view of an embodiment of the induction heatingassembly 14 in accordance with the present disclosure. The electricalconductors 46 couple to posts of the transformer 42 to circulate thealternating current from the transformer through the electricalconductors 46. Furthermore, the electrical conductors 46 may be hollowsuch that coolant flow may be received through a coolant inlet 78,circulate through the hollow interior of the electrical conductors 46,and exit via a coolant outlet 80. In certain embodiments, the secondaryinduction heating coil 44 is coupled to a secondary induction heatingcoil flux concentrator 82. For example, in certain embodiments, thesecondary induction heating coil flux concentrator 82 may be a box orother hollow structure formed from a highly permeable material, such asferrite, machined ferrite, and so forth. Additionally, in certainembodiments, the secondary induction heating coil flux concentrator 82may be coated with a heat sink compound configured to transfer heat tothe cooled elements of the secondary induction heating coil 44.

As described in greater detail herein, the transformer 42 and thesecondary induction heating coil 44 may be removably coupleable witheach other in certain embodiments, thereby enabling the secondaryinduction heating coil 44 to be interchanged with respect to thetransformer 42 during operation of the system 10. For example, incertain embodiments, a robotic positioning system may manipulate thepositioning of the induction heating assembly 14 and the couplingbetween the transformer 42 and the secondary induction heating coil 44to, for example, move the induction heating assembly 14 to an inductionheating coil changing station to detach a first secondary inductionheating coil 44 from the transformer 42, and attach a second secondaryinduction heating coil 44 to the transformer 42, thereby facilitatingdifferent secondary induction heating coils 44 to be used inductionheating of different types of welds, for example. In addition, incertain embodiments, the secondary induction heating coil fluxconcentrator 82 may similarly be removably coupleable with the secondaryinduction heating coil 44 to facilitate interchangeability of thesecondary induction heating coil flux concentrators 82. For example, thedifferent secondary induction heating coil flux concentrators 82 mayinclude different highly permeable materials in certain embodiments. Asused herein, the term “highly permeable” may be used to refer to anymaterial having a permeability substantially greater than air (e.g.,permeability of greater than 10, greater than 100, and so forth).

FIG. 6 is a perspective view of an embodiment of the transformer 42 inaccordance with the present disclosure. As illustrated, in certainembodiments, the transformer 42 includes an inlet conduit 84 thatfunctions as both a primary lead entrance/exit (e.g., for conveying ACpower for the induction heating) and a coolant inlet, and an outletconduit 86 that functions as a coolant outlet. The coolant that entersand exits through the coolant inlet and outlet of the transformer 42 isused to cool the internal components of the transformer 42. In addition,as illustrated in FIG. 6, in certain embodiments the transformer 42includes a plurality of secondary terminals 88 (e.g., with threadedstuds) that may be used to couple the transformer 42 to the electricalconductors 46 of the secondary induction heating coil 44 to convey theinduction heating power through the secondary induction heating coil 44(e.g., to the secondary induction heating coil flux concentrator 82).

FIG. 7 is a perspective view of an embodiment of the secondary inductionheating coil 44 in accordance with the present disclosure. Asillustrated, in general, it may be particularly advantageous to minimizethe distance between two generally parallel sections 90 of theelectrical conductors 46 of the secondary induction heating coil 44, andto maximize the length of these sections 90 to minimize the inductanceof the secondary induction heating coil 44. In addition, it may beadvantageous to position the transformer 42 as close as possible to theworkpiece 16 to minimize the required length of the secondary inductionheating coil 44. In addition, in certain embodiments, the secondaryinduction heating coil 44 may include a secondary plate 92 configured tomate with the bottom plate 76 of the transformer 42. For example, incertain embodiments, the secondary plate 92 includes a plurality ofopenings 94 through which the plurality of secondary terminals 88 of thetransformer 42 may fit, thereby establishing an electrical connectionbetween the bottom plate 76 of the transformer 42 and the secondaryplate 92 of the secondary induction heating coil 44.

In certain embodiments, the secondary plate 92 of the secondaryinduction heating coil 44 and the bottom plate 76 of the transformer 42include quick disconnect features 96 to enable the transformer 42 andthe secondary induction heating coil 44 to be quickly connected anddisconnected from each other such that the electrical and coolantconnections (e.g., facilitating induction heating power and coolant tobe transferred) between the transformer 42 and the secondary inductionheating coil 44 may be quickly established and removed. In suchembodiments, a valve may be used in the quick disconnect features 96 ofthe transformer 42 to ensure that the coolant flow is rerouted duringthe connection process. Such quick disconnect features 96 may beparticularly advantageous in systems that utilize robotic positioningsystems (e.g., which robotically manipulate positioning of the secondaryinduction heating coil 44 and/or the transformer 42 of the inductionheating assembly 14).

FIGS. 8A and 8B are side views of embodiments of the induction heatingassembly 14, illustrating the quick disconnect features 96 for groovewelds and fillet welds, respectively, in accordance with the presentdisclosure. The quick disconnect features 96 facilitate relatively quickcoupling and decoupling of the secondary induction heating coil 44 fromthe transformer 42 while creating and terminating, respectively,connections for coolant and power between the transformer 42 and thesecondary induction heating coil 44 during coupling and decoupling ofthe secondary induction heating coil 44 from the transformer 42. Thequick coupling and decoupling may be performed without the use of tools,and may be accomplished in a matter of seconds (e.g., less than 5seconds, less than 2 seconds, less than 1 second, or even faster), asopposed to more conventional coupling mechanisms, which may takesubstantially longer amounts of time.

FIGS. 5-8 generally illustrate embodiments where the transformer 42 andthe secondary induction heating coil 44 are directly coupled with eachother. In other embodiments, the transformer 42 and the secondaryinduction heating coil 44 may not be directly coupled to each other, butrather positionable remotely from each other. FIG. 9 is a side view ofan embodiment of the induction heating system 10, illustrating thetransformer 42 and the secondary induction heating coil 44 as separatecomponents that are independently positionable with respect to eachother, in accordance with the present disclosure. As illustrated, incertain embodiments, the transformer 42 may be directly mounted to abase structure 98 of a robotic positioning system 100 and, as such, mayremain in a relatively fixed position during operation of the system 10.In contrast, the secondary induction heating coil 44 is directly coupledto a remote arm 102 of the robotic positioning system 100, wherein thepositioning of the arms 102 is manipulated by the robotic positioningsystem 100 such that the secondary induction heating coil 44 may bemoved relative to the workpiece 16 during operation of the system 10. Incertain embodiments, quick disconnect features 96 may be used toconnect/disconnect the secondary induction heating coil 44 with theremote arm 102. For example, an arm plate 104 (e.g., similar to thebottom plate 76 of the transformer 42 embodiment illustrated in FIGS. 8Aand 8B, for example) may be configured to mate with the secondary plate92 of the secondary induction heating coil 44 to establish/removeelectrical and/or coolant connections between the transformer 42 and theremotely located secondary induction heating coil 44. To that end, incertain embodiments, the arm plate 104 may be connected to thetransformer 42 via a cable 106 (e.g., a cable bundle) configured toconvey the induction heating power and/or coolant between thetransformer 42 and the arm plate 104. For example, in certainembodiments, the cable 106 may include a flexible low inductancesecondary connection such as a coaxial liquid cooled litz cable, asillustrated in FIG. 10.

In other embodiments, as illustrated in FIGS. 11A and 11B, the secondaryinduction heating coil 44 may be remotely located from the transformer42 via a secondary connector 108 that includes two generally parallelplates 110, 112, for example, a top plate 110 and a bottom plate 112connected by two thin, generally parallel sheets 114 that connect thetop and bottom plates 110, 112 to each other. In certain embodiments,the two sheets 114 may be comprised of copper. In general, a first sheet114 functions to convey induction heating power to the secondaryinduction heating coil 44 whereas the second sheet 114 completes theelectrical circuit between the top and bottom plates 110, 112. As such,the two sheets 114 form a low inductance bus structure to transmit highfrequency AC power from the transformer 42 to a secondary inductionheating coil 44 via the top and bottom plates 110, 112. As illustrated,in certain embodiments, the two sheets 114 may extend between the topand bottom plates 110, 112 generally perpendicular to the top and bottomplates 110, 112. In certain embodiments, the two sheets 114 areseparated by a thin insulating layer 116 to electrically isolate the twosheets 114 from each other and minimize the inductance of the secondaryconnector 108.

It will be appreciated that the top plate 110 of the secondary connector108 may be configured to directly couple with the bottom plate 76 of thetransformer 42, and the bottom plate 112 of the secondary connector 108may be configured to directly couple with the secondary plate 92 of thesecondary induction heating coil 44 in similar manner as the bottomplate 76 of the transformer 42 and the secondary plate 92 of thesecondary induction heating coil 44 may directly couple with each otheras described herein. For example, in certain embodiments, the top andbottom plates 110, 112 of the secondary connector 108 may include quickdisconnect features 96 as described herein.

In addition, in certain embodiments, the secondary connector 108 mayinclude cooling tubes 118 disposed on each side of the two sheets 114 toenable the coolant from the transformer 42 to be circulated through thesecondary induction heating coil 44. In certain embodiments, a firstcooling tube 118 disposed on a first side of the sheets 114 may deliverthe coolant from the transformer 42 to the secondary induction heatingcoil 44, and a second cooling tube 118 disposed on a second, oppositeside of the sheets 114 may return the coolant from the secondaryinduction heating coil 44 to the transformer 42. FIG. 12 is aperspective view of an embodiment of the secondary connector 108 inaccordance with the present disclosure. It will be appreciated that acooling tube 118 is only illustrated on a first side of the sheets 114for illustrative purposes. As illustrated, a first cooling tube 118includes a coolant inlet 120 configured to connect with the transformer42 to receive coolant from the transformer 42 and a coolant outlet 122to connect with the secondary induction heating coil 44 such that thecoolant may be delivered from the transformer 42 to the secondaryinduction heating coil 44. It will be appreciated that the secondcooling tube 118 (not shown) may include similar inlets and outlets forfacilitating the return flow of coolant from the secondary inductionheating coil 44 to the transformer 42. As illustrated, in certainembodiments, the cooling tubes 118 may include a plurality of generallyparallel tube sections 124 that alternate back and forth on theirrespective sides of the sheets 114 to facilitate cooling of the sheets114 as well. In certain embodiments, proximate tube sections 124 may beconnected by flexible (e.g., rubber) hoses 126 that allow forflexibility during usage.

As described above, in certain embodiments, the transformer 42 and thesecondary induction heating coil 44 may be removably coupleable witheach other, thereby enabling the secondary induction heating coil 44 tobe interchanged with respect to the transformer 42 during operation ofthe system 10. Similarly, in certain embodiments, the secondaryinduction heating coil flux concentrator 82 may be removably coupleablewith the secondary induction heating coil 44 to facilitateinterchangeability of the secondary induction heating coil fluxconcentrators 82. As such, returning now to FIG. 9, in certainembodiments, the robotic positioning system 100 may be configured tomove the secondary induction heating coil 44 to an induction heatingcoil changing station 128 to, for example, detach the secondaryinduction heating coil 44 from the remote arm 102, and attach anothersecondary induction heating coil 44 to the remote arm 102, therebyfacilitating different secondary induction heating coils 44 to be usedfor induction heating of different types of welds, for example. Inaddition, in certain embodiments, the robotic positioning system 100 maybe configured to move the secondary induction heating coil 44 to theinduction heating coil changing station 128 to, for example, detach thesecondary induction heating coil flux concentrator 82 from the secondaryinduction heating coil 44, and attach another secondary inductionheating coil flux concentrator 82 to the secondary induction heatingcoil 44.

In certain embodiments, the transformer 42 and the secondary inductionheating coil 44 described herein may be combined into integratedinduction heating assemblies 14 that may, for example, beinterchangeable at the induction heating coil changing station 128.FIGS. 13-16 illustrate various embodiments of integrated inductionheating assemblies 14 for various different types of welds in accordancewith the present disclosure. For example, FIGS. 13 and 14 illustrateembodiments of an integrated induction heating assembly 14 specificallyconfigured for fillet welding, and FIGS. 15 and 16 illustrateembodiments of an integrated induction heating assembly 14 specificallyconfigured for groove welding. Each of the embodiments include a hollowelectrical conduit 130 that wraps around an interior of a housing 132 ofthe integrated induction heating assembly 14, and which includes aninlet 134 and an outlet 136 for circulating induction heating power andcoolant through the integrated induction heating assembly 14. It will beappreciated that the inlet and outlet 134, 136 are configured with quickdisconnect features 96 in certain embodiments to enableinterchangeability via the induction heating coil changing station 128(see FIG. 9).

The induction heating power conveyed through the electrical conduit 130is delivered to a highly permeable magnetic core 138 (e.g., inductionheating flux concentrator) specifically designed to focus flux to aparticular type of weld. For example, as illustrated in FIGS. 13 and 14,the integrated induction heating assembly 14 specifically design forfillet welding includes a magnetic core 138 that has two adjacent sides140, 142 that are generally aligned perpendicular with each other, andeach of the adjacent sides 140, 142 are generally aligned at a 45° anglewith respect to a central axis 144 of the integrated induction heatingassembly 14. As such, the distal end 146 of the magnetic core 138 isconfigured to approximately match the 90° angle formed by the workpiece16 on which the fillet weld is created. As illustrated in FIG. 14, thehousing 132 of the integrated induction heating assembly 14 includesopposite side walls 148 that extend from the housing 132 and aregenerally shaped similarly to the magnetic core 138 to also match the90° angle formed by a fillet weld joint. As also illustrated in FIG. 14,the electrical conduit 130 disposed within the housing 132 of theintegrated induction heating assembly 14 includes a first plurality ofwindings (e.g., turns) 150 that introduces the induction heating powerand coolant into the integrated induction heating assembly 14, and asecond plurality of windings (e.g., turns) 152 that complete theelectrical circuit and return the coolant from the integrated inductionheating assembly 14. In contrast, the integrated induction heatingassembly 14 illustrated in FIGS. 15 and 16 are more suited for groovewelding insofar as the magnetic core 138 forms a generally cylindricalshape and the opposite side walls 148 are generally rectangular to moreclosely match the shape of a particular groove weld joint. In general,the distal end of the magnetic core 138 illustrated in FIGS. 15 and 16includes a substantially flat surface configured to be disposedsubstantially parallel to the workpieces 16 forming the groove weldjoint therebetween.

As used herein, the term “substantially” (e.g., “substantiallyparallel”, “substantially perpendicular”, and so forth) is intended toaccount for variations due to manufacturing tolerance, operatingconditions (e.g., vibrations, thermal expansion, etc.), and so forth.For example, one of ordinary skill in the art will appreciate that wordssuch as “parallel”, “perpendicular” have precise mathematical and/orgeometric meanings. However, the terms “substantially parallel” and“substantially perpendicular allow for variations due to manufacturingtolerance, operating conditions (e.g., vibrations, thermal expansion,etc.), and so forth, while maintaining the spirit of the claimed term.

While only certain features of the present disclosure have beenillustrated and described herein, many modifications and changes willoccur to those skilled in the art. It is, therefore, to be understoodthat the appended claims are intended to cover all such modificationsand changes as fall within the true spirit of the present disclosure.

1. An induction heating system comprising: an induction heating powersupply unit configured to generate induction heating power; and aninduction heating assembly configured to use the induction heating powerreceived from the induction heating power supply unit to produce analternating current (AC) magnetic field that induces eddy currents intoa workpiece, wherein the induction heating assembly comprises a magneticcore disposed at a distal end of the induction heating assembly, whereina shape of the magnetic core corresponds to a shape of the workpiece. 2.The induction heating system of claim 1, wherein the magnetic corecomprises a highly permeable magnetic core configured to focus themagnetic field with respect to the workpiece, wherein a type of thehighly permeable magnetic core corresponds to a type of the workpiece.3. The induction heating system of claim 1, wherein the distal end ofthe magnetic core comprises adjacent perpendicular sides configured tobe disposed proximate adjacent members of a fillet weld workpiece whilethe magnetic field induces the eddy currents into the workpiece.
 4. Theinduction heating system of claim 1, wherein the distal end of themagnetic core comprises a substantially flat surface configured to bedisposed substantially parallel to a groove weld workpiece.
 5. Theinduction heating system of claim 1, comprising a robotic positioningsystem configured to manipulate positioning of the induction heatingassembly with respect to the workpiece.
 6. The induction heating systemof claim 5, comprising an induction heating assembly changing system,wherein the robotic positioning system is configured to move theinduction heating assembly to the induction heating assembly changingstation to decouple the induction heating assembly from the inductionheating power supply unit and to couple another induction heatingassembly to the induction heating power supply unit.
 7. The inductionheating system of claim 1, wherein the induction heating assembly is aninterchangeable induction heating assembly configured to electricallycouple to and decouple from the induction heating power supply unit. 8.The induction heating system of claim 7, wherein the interchangeableinduction heating assembly comprises a quick disconnect featureconfigured to facilitate quick coupling and decoupling of theinterchangeable induction heating assembly with the induction heatingpower supply unit.
 9. The induction heating system of claim 1, whereinthe induction heating assembly comprises a hollow electrical conductortube configured to flow a coolant.
 10. An induction heating systemcomprising: a transformer configured to receive alternating current (AC)power from an induction heating power supply unit, and to transform theAC power into induction heating power; and an interchangeable inductionheating coil configured to electrically couple to and decouple from thetransformer, to receive the induction heating power from thetransformer, and to produce an AC magnetic field that induces eddycurrents into a workpiece, wherein a shape of the interchangeableinduction heating coil corresponds to a shape of the workpiece.
 11. Theinduction heating system of claim 10, wherein the interchangeableinduction heating coil comprises a flux concentrator comprising a highlypermeable material configured to focus the AC magnetic field withrespect to the workpiece, wherein a type of the highly permeablematerial corresponds to a type of the workpiece.
 12. The inductionheating system of claim 10, wherein the interchangeable inductionheating coil comprises a quick disconnect feature configured tofacilitate quick coupling and decoupling of the interchangeableinduction heating coil with the transformer, wherein the interchangeableinduction heating coil comprises an electrical conductor loop thatextends substantially orthogonally from the quick disconnect feature,extends from the quick disconnect feature at an angle, or comprises ahollow tube configured to flow a coolant.
 13. The induction heatingsystem of claim 10, comprising a robotic positioning system configuredto manipulate positioning of the interchangeable induction heating coilwith respect to the workpiece.
 14. The induction heating system of claim13, comprising an induction heating coil changing system, wherein therobotic positioning system is configured to move the interchangeableinduction heating coil to the induction heating coil changing station toelectrically decouple the interchangeable induction heating coil fromthe transformer and to electrically couple another interchangeableinduction heating coil to the transformer.
 15. The induction heatingsystem of claim 10, comprising a cable configured to electrically couplethe transformer to the interchangeable induction heating coil.
 16. Theinduction heating system of claim 10, comprising a bus structureconfigured to physically couple the transformer to the interchangeableinduction heating coil.
 17. The induction heating system of claim 16,wherein the bus structure comprises a first plate configured tophysically couple the bus structure to the transformer, a second plateconfigured to physically couple the bus structure to the interchangeableinduction heating coil, and first and second substantially parallelsheets that connect the first and second plates.
 18. The inductionheating system of claim 17, wherein the first and second plates aresubstantially parallel, and the first and second sheets extendperpendicular from the first and second plates.
 19. The inductionheating system of claim 17, wherein the first and second sheets areseparated by a layer of insulation.
 20. The induction heating system ofclaim 17, comprising a first electrical conductor tube disposed adjacentthe first sheet, and a second electrical conductor tube disposedadjacent the second sheet, wherein the first electrical conductor tubeis configured to deliver a coolant to the interchangeable inductionheating coil, and the second electrical conductor tube is configured toreturn the coolant from the interchangeable induction heating coil.